Staged load amplified power closure system

ABSTRACT

A closure assembly includes a housing, a sensor, a door, and a primary actuator. The sensor is disposed within the housing. The door is supported by the housing and is movable between a closed position and an open position. The sensor is exposed when the door is in the open position. The primary actuator is operable to (i) apply a first force on the door to move the door from the closed position to the open position and (ii) apply a second force on the door to move the door from the closed position to the open position when the first force does not move the door into the open position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/076,907 filed on Nov. 7, 2014, the entire disclosureof which is incorporated herein by reference.

FIELD

The present disclosure relates generally to a staged load amplifiedclosure system, and more particularly to a system and method for stagedload closure and deployment of a sensor or camera.

BACKGROUND

This section provides background information related to the presentdisclosure and is not necessarily prior art.

Many motor vehicles now come equipped with some variation of a cameraand sensor system to provide real-time monitoring or viewing of an areanear the motor vehicle. For example, cameras, sensors, or both are oftenpositioned on the front of the vehicle or on the rear of the motorvehicle. The cameras and sensors can detect the areas surrounding thevehicle that are not otherwise viewable with the conventional mirrors.Such cameras and sensors can be used to assist the vehicle operator inparking or maneuvering the vehicle during normal operation, for example.

To provide a consistent field of view, many camera and sensor systems donot include a cover and are fixedly directed at the space they areintended to monitor. Uncovered cameras and sensors are prone to damagefrom environmental conditions and exposure, including damage from dirtand stone chipping, and also from human intervention, including theft.

To better protect the camera, sensor, or other device, a deployablesystem may be utilized. In a deployable system, the sensor, camera, orother suitable device, may utilize an electric motor to drive the systembetween an open or “deployed” position and a closed or “stowed”position. The motor may be linked to a set of gears to provide a speedand torque realignment and a set of links and/or cams to provide themotion to activate the desired deployment and stowing of the camera orsensor. The system may be activated by various actions of a vehicleuser. For example, to deploy the system, the vehicle user may place agear selector into a reverse position, which may activate the electricmotor in a first direction. To stow the system, the vehicle user mayplace the gear selector into a park, neutral, or drive position, whichmay activate the electric motor in a second direction opposite the firstdirection. In order to ensure that the system functions properly, it maybe necessary to utilize a motor, gears, and/or linkage that issufficiently strong to overcome various operational system loadsincurred during deployment. For example, it may be necessary to utilizea motor, gears, and/or linkages that are sufficiently strong to overcomevarious forces that might otherwise prevent the system from deploying.In particular, it may be necessary to utilize a motor, gears, and/orlinkages that can overcome friction, ice, mud, mechanical sealing, etc.that might otherwise prevent the system from deploying. Such motors,gears, and/or linkages may be expensive, heavy, and occupy a largepackaging space within the vehicle.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

According to one aspect, a closure assembly is provided. The closureassembly may include a housing, a sensor, a door, and a primaryactuator. The sensor may be disposed within the housing. The door may besupported by the housing and may be movable between a closed positionand an open position. The sensor may be exposed when the door is in theopen position. The primary actuator may be operable to (i) apply a firstforce on the door to move the door from the closed position to the openposition and (ii) apply a second force on the door to move the door fromthe closed position to the open position when the first force does notmove the door into the open position.

In some implementations, the second force is greater than the firstforce.

In some implementations, the door includes a control feature and theprimary actuator includes a pin that engages the control feature torotate the door from the closed position to the open position.

In some configurations, the control feature includes a slot. The slotmay include a first cam surface and a second cam surface. In someimplementations, the first cam surface is operable to control themovement of the door from the closed position to the open position, andthe second cam surface is operable to control the movement of the doorfrom the open position to the closed position.

In some configurations, the control feature includes a ramped surface.In some implementations, the ramped surface includes a concave portionand a convex portion extending from the concave portion.

In some configurations, the closure assembly includes a spindle and adriver. The driver may be operable to rotate the spindle. In someimplementations, the spindle includes a first ramp that engages theprimary actuator and a second ramp that engages a secondary actuator. Insome configurations, the driver includes at least one of a motor and ashape-memory alloy that rotates the spindle.

In some implementations, the driver rotates the spindle in a firstdirection about an axis of rotation to move the door from the closedposition to the open position. The driver may rotate the spindle in thefirst direction about the axis of rotation to rotate the door from theopen position to the closed position.

In some configurations, the door is supported by the housing forrotation about an axis. The first force may produce a first torque aboutthe first axis and the second force may produce a second torque aboutthe first axis. In some implementations, the second torque is greaterthan the first torque.

According to another aspect, a closure assembly is provided. The closureassembly may include a housing, a sensor, a door, a primary actuator,and a secondary actuator. The sensor may be disposed within the housing.The door may be supported by the housing and may be movable between aclosed position and an open position. The sensor may be exposed when thedoor is in the open position. The primary actuator may be operable totransmit a first impact to the door to move the door from the closedposition to the open position. The secondary actuator may be operable totransmit a second impact to the door to move the door from the closedposition to the open position when the first impact does not move thedoor into the open position.

In some implementations, a force generated by the second impact isgreater than a force generated by the first impact.

In some configurations, the closure assembly includes an energy storagedevice configured to store a first amount of energy and a second amountof energy greater than the first amount of energy. The first amount ofenergy may produce the first impact, and the second amount of energy mayproduce the second impact.

According to yet another aspect, a method of operating a closureassembly is provided. The closure assembly may include a housing, a doormovably coupled to the housing, and an actuator. The method may includestoring a first amount of energy in an energy storage device andreleasing the first amount of energy to move the door from a closedstate to an open state. The method may further include storing a secondamount of energy in the energy storage device if the door remains in theclosed state following release of the first amount of energy. The secondamount of energy may be greater than the first amount of energy. Themethod may also include releasing the second amount of energy to movethe door from the closed state to the open state.

In some implementations, the method may also include exposing a sensorwhen the door is in the open state and hiding the sensor when the dooris in the closed state.

In some implementations, releasing the first amount of energy includesproducing a first momentum impulse with the first amount of energy tomove the door from a closed state to an open state.

In some implementations, releasing the second amount of energy includesproducing a second momentum impulse to move the door from the closedstate to the open state. The second momentum impulse may be greater thanthe first momentum impulse.

According to a further aspect, a method of operating a closure assemblyis provided. The closure assembly may include a housing, a door movablycoupled to the housing, and an actuator. The method may include engagingthe door with the actuator to apply a first force to move the door froma closed state to an open state to expose a sensor. The method may alsoinclude engaging the door with the actuator to apply a second forcegreater than the first force to move the door from the closed state tothe open state to expose the sensor when the first force fails to movethe door from the closed state to the open state.

In some implementations, the door is supported by the housing forrotation about a first axis. The first force may produce a first torqueabout the first axis and the second force producing a second torqueabout the first axis.

In some implementations, engaging the door with the actuator to producethe second force includes producing a first occurrence of the secondforce and a second occurrence of the second force.

In some configurations, the door includes a control feature and theactuator includes a pin. Engaging the door with the actuator may includemoving the pin along a surface of control feature.

In some implementations, the closure assembly may include a spindlehaving a ramp surface. The method may further include rotating thespindle about an axis of rotation in a first direction such that theactuator engages the ramp surface to produce the first force.

In some implementations, the method may also include rotating thespindle in the first direction about the axis of rotation to produce thefirst force and the second force, and rotating the spindle in the firstdirection about the axis of rotation to produce a third force. The thirdforce may be opposite the first force and the second force to move thedoor from the open state to the closed state.

In some implementations, the second force includes an impact force. Insome configurations, the door is supported by the housing for rotationabout a first axis. The first force may produce a first torque about thefirst axis and the impact force may produce a second torque about thefirst axis.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected configurations and not all possible implementations, and arenot intended to limit the scope of the present disclosure.

FIG. 1A is a top view of a vehicle having a deployable sensor assemblyin accordance with the principles of the present disclosure;

FIG. 1B is an end view of the vehicle of FIG. 1A, showing the deployablesensor assembly in a deployed position in accordance with the principlesof the present disclosure;

FIG. 2A is a perspective view of a deployable sensor assembly in a firstposition according to the principles of the present disclosure;

FIG. 2B is a perspective view of the deployable sensor assembly of FIG.2A in a second position according to the principles of the presentdisclosure;

FIG. 2C is a perspective view of the closure assembly of FIG. 2A in athird position according to the principles of the present disclosure;

FIG. 2D is a perspective view of the closure assembly of FIG. 2A in afourth position according to the principles of the present disclosure;

FIG. 2E is a perspective view of the closure assembly of FIG. 2A in afifth position according to the principles of the present disclosure;

FIG. 2F is a perspective view of the closure assembly of FIG. 2A in asixth position according to the principles of the present disclosure;

FIG. 2G is a perspective view of the closure assembly of FIG. 2A in aseventh position according to the principles of the present disclosure;

FIG. 2H is a perspective view of the closure assembly of FIG. 2A in aneighth position according to the principles of the present disclosure;

FIG. 3 is a top view of the closure assembly of FIG. 2A in the seventhposition;

FIG. 4 is an exploded view of the closure assembly of FIG. 2A;

FIG. 5A is a perspective view of another closure assembly in a firstposition according to the principles of the present disclosure;

FIG. 5B is a perspective view of the closure assembly of FIG. 5A in asecond position according to the principles of the present disclosure;

FIG. 5C is a perspective view of the closure assembly of FIG. 5A in athird position according to the principles of the present disclosure;

FIG. 6 is an exploded view of the closure assembly of FIG. 5A;

FIG. 7 is a perspective view of another closure assembly according tothe principles of the present disclosure;

FIG. 8A is a sectional view of the closure assembly of FIG. 7 in a firstposition according to the principles of the present disclosure;

FIG. 8B is a sectional view of the closure assembly of FIG. 7 in asecond position according to the principles of the present disclosure;and

FIG. 9 is an exploded view of the closure assembly of FIG. 7.

Corresponding reference numerals indicate corresponding parts throughoutthe drawings.

DETAILED DESCRIPTION

Example configurations will now be described more fully with referenceto the accompanying drawings. Example configurations are provided sothat this disclosure will be thorough, and will fully convey the scopeof the disclosure to those of ordinary skill in the art. Specificdetails are set forth such as examples of specific components, devices,and methods, to provide a thorough understanding of configurations ofthe present disclosure. It will be apparent to those of ordinary skillin the art that specific details need not be employed, that exampleconfigurations may be embodied in many different forms, and that thespecific details and the example configurations should not be construedto limit the scope of the disclosure.

The terminology used herein is for the purpose of describing particularexemplary configurations only and is not intended to be limiting. Asused herein, the singular articles “a,” “an,” and “the” may be intendedto include the plural forms as well, unless the context clearlyindicates otherwise. The terms “comprises,” “comprising,” “including,”and “having,” are inclusive and therefore specify the presence offeatures, steps, operations, elements, and/or components, but do notpreclude the presence or addition of one or more other features, steps,operations, elements, components, and/or groups thereof. The methodsteps, processes, and operations described herein are not to beconstrued as necessarily requiring their performance in the particularorder discussed or illustrated, unless specifically identified as anorder of performance. Additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” “attached to,” or “coupled to” another element or layer,it may be directly on, engaged, connected, attached, or coupled to theother element or layer, or intervening elements or layers may bepresent. In contrast, when an element is referred to as being “directlyon,” “directly engaged to,” “directly connected to,” “directly attachedto,” or “directly coupled to” another element or layer, there may be nointervening elements or layers present. Other words used to describe therelationship between elements should be interpreted in a like fashion(e.g., “between” versus “directly between,” “adjacent” versus “directlyadjacent,” etc.). As used herein, the term “and/or” includes any and allcombinations of one or more of the associated listed items.

The terms first, second, third, etc. may be used herein to describevarious elements, components, regions, layers and/or sections. Theseelements, components, regions, layers and/or sections should not belimited by these terms. These terms may be only used to distinguish oneelement, component, region, layer or section from another region, layeror section. Terms such as “first,” “second,” and other numerical termsdo not imply a sequence or order unless clearly indicated by thecontext. Thus, a first element, component, region, layer or sectiondiscussed below could be termed a second element, component, region,layer or section without departing from the teachings of the exampleconfigurations.

With reference to FIGS. 1A and 1B, a vehicle 10 is provided. The vehicle10 may be any known variety of vehicle, such as a car, a truck, or a vanfor example. The vehicle 10 may include a front portion 12, a rearportion 14, a first side portion 16, a second side portion 18, and oneor more deployable sensor assemblies 20. In some configurations, thevehicle 10 may include four sensor assemblies 20. For example, thevehicle 10 may include a first sensor assembly 20 disposed on the frontportion 12 (e.g., disposed proximate a front bumper), a second sensorassembly 20 disposed on the rear portion 14 (e.g., disposed proximate arear bumper), a third sensor assembly 20 disposed on the first sideportion 16 (e.g., disposed proximate a driver's side door), and a fourthsensor assembly 20 disposed on the second side portion 18 (e.g.,disposed proximate a passenger's side door). As will be explained inmore detail below, the position of each sensor assembly 20 may beselectively controllable relative to the vehicle 10. In particular, thesensor assemblies 20 may be movable (e.g., rotatable, pivotable,translatable, etc.) between a stowed or closed position (FIG. 2A) and adeployed or open position (FIGS. 1B and 2B). In the open position, thesensor assembly 20 can communicate with an end user (e.g., a driver ofthe vehicle 10) via audio and/or visual signals (e.g., via aninfotainment display) in order to notify the end user of variousenvironmental conditions in an area surrounding the vehicle 10.

With reference to FIGS. 2A-4, the sensor assembly 20 may include ahousing subassembly 22, a door subassembly 24, an actuator subassembly26, and a driver subassembly 28. As illustrated in FIG. 4, the housingsubassembly 22 may include a base 32 and a cover 34. The base 32 mayinclude a lower surface 35, an aperture 36 and a rotation feature 38(e.g., a hub or an axle mount). The aperture 36 may extend through thebase 32 such that the lower surface 35 generally surrounds the aperture36. The rotation feature 38 may define a first axis of rotation 40. Aswill be explained in more detail below, in an assembled configuration,the aperture 36 and rotation feature 38 may receive the door subassembly24. In particular, the door subassembly 24 may be mounted to therotation feature 38 for rotation about the first axis of rotation 40,such that the door subassembly 24 is receivable within the aperture 36in a stowed or closed position (FIG. 2A) and a deployed or open position(FIG. 2B).

The cover 34 may include a chamber 42 having a slot 43 and a stopsurface 44. The chamber 42 may define a generally cylindrical construct(e.g., a circular cylinder, a rectangular cylinder, or other polygonalcylinder) defining a path (e.g, linear path and/or an arcuate path)having a first translational axis 46 extending through the stop surface44. As illustrated in FIG. 2A, the first translational axis 46 mayextend in a direction substantially perpendicular (e.g., +/− 5 degrees)to the first axis of rotation 40. As will be explained in more detailbelow, in the assembled configuration, the chamber 42 may receive theactuator subassembly 26 for translation along the first translationalaxis 46.

As illustrated in at least FIG. 4, the door subassembly 24 may include adoor 50 and a sensing device 52, such as a camera or a motion sensor,for example, an axle 54, and a biasing member 56. The door 50 mayinclude a baseplate 58, a first support arm 60, and a second support arm62. The baseplate 58 may include an upper surface 64 and a lower surface65 opposite the upper surface 64. In some configurations, the lowersurface 65 includes a substantially planar construct such that when thedoor subassembly 24 is received by the aperture 36 of the base 32, thelower surface 65 of the baseplate 58 is substantially coplanar with thelower surface 35 of the base 32.

The first and second support arms 60, 62 may extend from the uppersurface 64 of the baseplate 58. For example, in some configurations thefirst and second support arms 60, 62 may extend in a direction generallyorthogonal to the upper surface 64 of the baseplate 58. The firstsupport arm 60 may include a rotation feature 66 (e.g., a hub or anaxle). The second support arm 62 may include a rotation feature 68(e.g., a hub or an axle) and a control feature 70. In the assembledconfiguration, the rotation features 66, 68 of the first and secondsupport arms 60, 62, respectively, may be coupled to the rotationfeature 38 of the base 32 for rotation about the first axis of rotation40. For example, in some configurations, the rotation features 38, 66,68 may each include a hub. The axle 54 may be substantially aligned withthe first axis of rotation 40 and disposed within one or more of therotation features 38, 66, 68 such that the door subassembly 24 can pivotabout the axis of rotation 40 between the closed position (FIG. 2A) andthe open position (FIG. 2B). In some configurations, the biasing member56 may include a spring (e.g., a torsional spring, a compression spring,a leaf spring, etc.) disposed about the axis of rotation 40 (e.g.,disposed about the axle 54) and biasing the door subassembly 24 from theopen position (FIG. 2B) to the closed position (FIG. 2A), or vice versa.

The control feature 70 may include slot extending through the secondsupport arm 62. In some configurations, the slot of the control feature70 may include a generally L-shaped construct having a first leg 71extending transversely from a second leg 73. The first and second legs71, 73 may include an L-shaped upper surface 72, an L-shaped lowersurface 74 opposite the L-shaped upper surface 72, and end surfaces 76,78 extending from the upper surface 72 to the lower surface 74. In otherconfigurations, the upper surface 72 may include a concave configurationand the lower surface 74 may include a convex configuration. In thisregard, a radius of curvature of the upper surface 72 may besubstantially equal to a radius of curvature of the lower surface 74such that the upper surface 72 is substantially parallel to the lowersurface 74. As will be explained in more detail below, the controlfeature 70 can control the movement of the door 50 relative to thehousing subassembly 22. In this regard, the upper surface 72 may define,and be referred to herein, as a cam surface 72 (e.g., a first camsurface), and the lower surface 74 may define, and be referred toherein, as a cam surface 74 (e.g., a second cam surface). The camsurfaces 72, 74 can control the movement of the door 50 (e.g., openingand/or closing) by engaging with the actuator subassembly 26.

The sensing device 52 may be coupled to the door 50. For example, insome configurations the sensing device 52 may be supported by the uppersurface 64 of the baseplate 58 between the first and second support arms60, 62. Accordingly the sensing device 52 may rotate with the door 50between the open position (FIG. 2B) and the closed position (FIG. 2A)such that the sensing device 52 can sense (e.g., capture video) anenvironment outside of the housing subassembly 22 in the open position.

As illustrated in FIGS. 2A and 4, the actuator subassembly 26 mayinclude a primary actuator 80, a secondary actuator 82, and an energystorage device such as a biasing member 84. The primary actuator 80 mayinclude a block 88, first pin 90, and a second pin 92. The block 88 mayinclude a generally hollow construct defining an inner chamber 94. Insome configurations, the block 88 may include a generally circularcylindrical shape. It will be appreciated, however, that the block 88may include other cross-sectional shapes and configurations, such as anellipse, a square, or other polygonal shape, within the scope of thepresent disclosure. The block 88 may include a proximal end 96, a distalend 98 opposite the proximal end 96, and a slot 100. The slot 100 mayextend through the block 88 and into the chamber 94 from the distal end98 toward the proximal end 96. The proximal end 96 of the block 88 maydefine a stop surface 101 facing the distal end 98 of the block 88.

The first pin 90 may extend from a first lateral side 102 of the block88, and the second pin 92 may extend from a second lateral side 104 ofthe block 88. The first lateral side 102 may be opposite the secondlateral side 104. Accordingly, the first pin 90 may extend in adirection substantially parallel to the second pin 92. In someconfigurations, the first pin 90 may be aligned and/or collinear withthe second pin 92. In this regard, in some configurations, the first andsecond pins 90, 92 may define a integrally and/or monolithically formedand linearly extending construct.

In the assembled configuration, the slot 100 may extend in a directionsubstantially parallel to the first translational axis 46. In thisregard, the primary actuator 80 may be disposed within the chamber 42 ofthe cover 34 such that the distal end 98 faces the stop surface 44 ofthe cover 34, and such that the chamber 42 is in communication with theinner chamber 94 of the block 88. In particular, the primary actuator 80may be translatably disposed within the chamber 42 such that the block88 can translate in a direction substantially parallel to the firsttranslational axis 46 and to the slot 100. In this regard, in theassembled configuration, the first pin 90 may extend through the slot 43of the cover 34, and the second pin 92 may extend through the controlfeature 70 (e.g., the arcuate slot) of the door 50.

The secondary actuator 82 may include a hammer 108 and a third pin 110.The hammer 108 may define a generally prismatic construct extending froma proximal end 114 to a distal end 116. The third pin 110 may extendfrom a first lateral side 118 of the hammer 108. The mass of thesecondary actuator 82, including the hammer 108 and/or the third pin110, may be greater than a mass of the primary actuator 80. For example,the mass of the secondary actuator 82 may be between 20 grams and 100grams. In this regard, the secondary actuator 82, including the hammer108 and/or the third pin 110, may be formed from a metal such as steel,zinc, iron, or an alloy thereof.

In the assembled configuration, the secondary actuator 82 may bedisposed within the inner chamber 94 of the primary actuator 80. Inparticular, the secondary actuator 82 may be translatably disposedwithin the inner chamber 94 such that the secondary actuator 82 cantranslate in a direction substantially parallel to the firsttranslational axis 46. In this regard, the third pin 110 may betranslatably disposed within the slot 100 of the block 88 and within theslot 43 of the cover 34. Accordingly, the third pin 110 may extend in adirection substantially parallel to the first pin 90 of the primaryactuator 80.

The biasing member 84 may include a proximal end 120 and a distal end121. In some configurations, the biasing member 84 may be a compressioncoil spring extending from the proximal end 120 to the distal end 121.In the assembled configuration, the biasing member 84 may be disposedwithin the chamber 94 of the block 88. For example, the biasing member84 may be disposed within the chamber 94 such that the proximal end 120engages the hammer 108 of the secondary actuator 82 and the distal end121 engages the stop surface 44 of the cover 34. Accordingly, as will beexplained in more detail below, upon translation of the secondaryactuator 82 in the direction of the stop surface 44, the secondaryactuator 82 may compress the biasing member 84 in order to increase theelastic potential energy stored within the biasing member 84.

As illustrated in FIGS. 2A and 4, the driver subassembly 28 may includea spindle 122 and a driver 124. The spindle 122 may include a proximalend 126, a distal end 128, a primary ramp 130, a secondary ramp 132, anda drive mechanism 134. The spindle 122 may extend from the proximal end126 to the distal end 128 along a second axis of rotation 136. Asillustrated in FIG. 2A, the second axis of rotation 136 may extend in adirection substantially perpendicular (e.g., +/− 5 degrees) to the firstaxis of rotation 40.

The primary ramp 130 may extend radially outwardly from the spindle 122from a proximal end 138 to a distal end 140. The primary ramp 130 mayextend helically about the second axis of rotation 136 such that theproximal end 138 is aligned with the distal end 140 about the secondaxis of rotation 136. In particular, the proximal and distal ends 138,140 may define a line extending in a direction substantially parallel tothe second axis of rotation 136.

The secondary ramp 132 may extend radially outwardly from the spindle122 from a proximal end 142 to a distal end 144. The secondary ramp 132may extend helically about the second axis of rotation 136 such that theproximal end 142 is offset relative the distal end 140 about the secondaxis of rotation 136. In particular, as illustrated in FIG. 3, theproximal and distal ends 142, 144 of the secondary ramp 132 may define agap 146 extending about the second axis of rotation 136. The distal end144 of the secondary ramp 132 may be aligned with the proximal anddistal ends 138, 140 of the primary ramp 130, such that the distal end144 of the secondary ramp 132 and the proximal and distal ends 138, 140of the primary ramp 130 define a line extending in a directionsubstantially parallel to the second axis of rotation 136.

The drive mechanism 134 may include a gear wheel 150. In someconfigurations, the gear wheel 150 may be disposed proximate to theproximal end 126 of the spindle 122. The gear wheel 150 may include aseries of gear teeth 152. Rotation of the gear wheel 150 may cause thespindle 122 to rotate about the second axis of rotation 136.

In some configurations, the driver 124 may include one or moremechanisms configured to rotate the spindle 122 about the second axis ofrotation 136. For example, as illustrated in FIGS. 2A-4, in someconfigurations, the driver 124 may include an electric motor. As will beexplained in more detail below, however, the driver 124 may includeother mechanisms (e.g., a shape-memory alloy driven mechanism, ahydraulically driven mechanism, a pneumatically driven mechanism, etc.)configured to rotated the spindle 122 about the second axis of rotation136, within the scope of the present disclosure. The driver 124 mayfurther include a driveshaft 158 and a worm gear 160. In the assembledconfiguration, the worm gear 160 may be engaged with the gear teeth 152of the drive mechanism 134 such that rotation of the worm gear 160 bythe driver 124 causes the rotation of the spindle 122 about the secondaxis of rotation 136.

A method of operating the sensor assembly 20 will now be described withreference to FIGS. 2A-2H. As illustrated in FIG. 2A, a first mode ofoperation may begin with the door subassembly 24 in a closed positionsuch that the lower surface 65 of the baseplate 58 is substantiallycoplanar with the lower surface 35 of the base 32. In the closedposition, the second pin 92 of the primary actuator 80 may be disposedin the first leg 71 of the control feature 70. In particular, the end 76and/or the upper surface 72 of the control feature 70 may engage thesecond pin 92 such that the door subassembly 24 is supported in theclosed position by the second pin 92.

In a first mode of operation, the first pin 90 may be disposed on theprimary ramp 130. In particular, when the door subassembly 24 is in theclosed position, the first pin 90 may be disposed at the distal end 140of the primary ramp 130. During the first mode of operation, the driversubassembly 28 may receive an instruction to activate the driver 124. Inparticular, the driver 124 (e.g., a motor) may receive an activationsignal causing the driver 124 to rotate in a first direction. Forexample, in some configurations, an end user of the motor vehicle mayshift the motor vehicle into reverse, which may send the activationsignal to the driver 124, causing the driveshaft 158 and the worm gear160 to rotate in the first direction.

As the worm gear 160 rotates in the first direction, the worm gear 160engages the gear teeth 152 of the drive mechanism 134, causing thespindle 122 to rotate in a second direction about the second axis ofrotation 136. As the spindle 122 rotates in the second direction, thefirst pin 90 may disengage the primary ramp 130. In particular, thefirst pin 90 may translate in a first direction, substantially parallelto the translational axis 46, from the distal end 140 of the primaryramp 130 to the proximal end 138 of the primary ramp 130. In thisregard, the biasing member 84 may apply a force F1 on the secondaryactuator 82, urging the secondary actuator 82 in the direction of theprimary actuator 80, and, in turn, urging the primary actuator 80 in thefirst direction. As the first pin 90 translates in the first direction,the first pin 90 of the primary actuator 80 and the third pin 110 of thesecondary actuator 82 may translate within the slot 43 of the cover 34,and the second pin 92 of the primary actuator 80 may translate withinthe control feature 70 of the door subassembly 24. For example, thesecond pin 92 may disengage the end 76 and/or the upper surface 72 ofthe control feature 70 and engage the lower surface 74 of the controlfeature 70. In this regard, the second pin 92 may apply a force on thelower surface 74, creating a first torque impulse T1 about therotational axis 40 of the door subassembly 24, and causing the doorsubassembly 24 to rotate about the rotational axis 40. In someconfigurations, the biasing member 56 may cause the door subassembly 24to rotate about the rotational axis 40 in lieu of, or in addition to,the first torque T1 created by the second pin 92. As the doorsubassembly 24 rotates about the rotational axis 40 into the openposition (FIG. 2B), the second pin 92 may translate within the controlfeature 70 from the end 76 to the end 78 until the door subassembly 24reaches the open position.

When the door subassembly 24 reaches the open position, the driversubassembly 28 may receive an instruction to deactivate the driver 124.In particular, the driver subassembly 28 may receive a signal causingthe driveshaft 158 to stop rotating. For example, the sensor assembly 20may include a first limit switch 170. In some configurations, the firstlimit switch 170 may be disposed between the door subassembly 24 and thehousing subassembly 22. Accordingly, when the door subassembly 24rotates from the first position (FIG. 2A) to the second position (FIG.2B), the first limit switch 170 may be switched to an “OFF” position,thereby deactivating the driver 124.

In a second mode of operation, the first pin 90 may be disposed on theprimary ramp 130. In particular, when the door subassembly 24 is in theopen position (FIG. 2B), the first pin 90 may be disposed at theproximal end 138 of the primary ramp 130. During the second mode ofoperation, the driver subassembly 28 may receive an instruction toactivate the driver 124. In particular, the driver 124 (e.g., a motor)may receive an activation signal causing the driver 124 to rotate in thefirst direction. For example, in some configurations, an end user of themotor vehicle may shift the motor vehicle into neutral or drive, whichmay send the activation signal to the driver 124, causing the driveshaft158 and the worm gear 160 to rotate in the first direction.

As the worm gear 160 rotates in the first direction, the worm gear 160engages the gear teeth 152 of the drive mechanism 134, causing thespindle 122 to rotate in the second direction about the second axis ofrotation 136. With reference to FIG. 2C, as the spindle 122 rotates inthe second direction, the first pin 90 may move along the primary ramp130. In particular, the first pin 90 may move along the helical path ofthe primary ramp 130 from the proximal end 138 of the primary ramp 130to the distal end 140 of the primary ramp 130. As the first pin 90 movesalong the primary ramp 130, the first pin 90 of the primary actuator 80and the third pin 110 of the secondary actuator 82 may translate withinthe slot 43 of the cover 34, and the second pin 92 of the primaryactuator 80 may translate within the control feature 70 of the doorsubassembly 24, as the primary and secondary actuators 80, 82 translatealong the translational axis 46 within the chamber 42 of the cover 34.In this regard, the second pin 92 may disengage the end 78 of thecontrol feature 70 and engage the upper surface 72 of the controlfeature 70. The second pin 92 may apply a force on the upper surface 72,creating a torque about the rotational axis 40 of the door subassembly24, and causing the door subassembly 24 to rotate about the rotationalaxis 40. The torque created by the second pin 92 may be greater than anopposing torque generated by the biasing member 56 and/or the biasingmember 84. Accordingly, as the primary and secondary actuators 80, 82translate within the chamber 42 toward the stop surface 44, thesecondary actuator 82 may compress the biasing member 84 as the secondpin 92 moves the door subassembly 24 into the closed position (FIG. 2A).

When the door subassembly 24 reaches the closed position, the driversubassembly 28 may receive an instruction to deactivate the driver 124.In particular, the driver subassembly 28 may receive a signal causingthe driveshaft 158 to stop rotating. For example, the sensor assembly 20may include a second limit switch 172. In some configurations, thesecond limit switch 172 may be disposed between the actuator subassembly26 and the housing subassembly 22. Accordingly, when the doorsubassembly 24 rotates from the second position (FIG. 2B) to the firstposition (FIG. 2A), the second limit switch 172 may be switched to an“OFF” position, thereby deactivating the driver 124.

A third mode of operation may begin with the door subassembly 24 in theclosed position (FIG. 2A), as previously described, such that the firstpin 90 is disposed on the primary ramp 130. During the third mode ofoperation, the driver subassembly 28 may receive an instruction toactivate the driver 124. In particular, the driver 124 (e.g., a motor)may receive an activation signal causing the driver 124 to rotate in afirst direction. For example, in some configurations, the end user ofthe motor vehicle may shift the motor vehicle into reverse, which maysend the activation signal to the driver 124, causing the driveshaft 158and the worm gear 160 to rotate in the first direction.

As the worm gear 160 rotates in the first direction, the worm gear 160engages the gear teeth 152 of the drive mechanism 134, causing thespindle 122 to rotate in a second direction about the second axis ofrotation 136. With reference to FIG. 2D, as the spindle 122 rotates inthe second direction, the first pin 90 may disengage the primary ramp130, and the second pin 92 may disengage the upper surface 72 of thecontrol feature 70. In this regard, the force F1 of the biasing member84 on the secondary actuator 82 may urge the primary actuator 80 in thefirst direction such that the second pin 92 engages the lower surface 74of the control feature 70. As previously described, however, during thethird mode of operation, the door subassembly 24 may be prevented fromrotating about the rotational axis 40. For example, friction betweenvarious moving components in the sensor assembly 20, or an obstruction,such as ice or dirt, may prevent the door subassembly 24 from rotatinginto the open position (FIG. 2B). In particular, the torque generated bythe force(s) preventing the door subassembly 24 from rotating into theopen position may be greater than the first torque Ti generated by theforce F1 of the biasing member 84. Accordingly, when the first pin 90disengages the primary ramp 130, as previously described, the doorsubassembly 24 may not trigger the first limit switch 170. If the firstlimit switch 170 is not triggered because, for example, the doorsubassembly 24 does not rotate into the open position when the first pin90 disengages the primary ramp 130, the driver 124 may remain activatedsuch that the driveshaft 158 continues to rotate the spindle 122 in thesecond direction about the second axis of rotation 136.

As the spindle 122 continues to rotate, subsequent to the first pin 90disengaging the primary ramp 130, the third pin 110 of the secondaryactuator 82 may engage the secondary ramp 132. With reference to FIG.2E, as the spindle 122 continues rotating in the second direction, thefirst pin 90 remains essentially stationary while the the third pin 110may engage the proximal end 142 of the secondary ramp 132 and continuemoving along the secondary ramp 132 from the proximal end 142 to thedistal end 144. In this regard, as the third pin 110 moves along thesecondary ramp 132, the secondary actuator 82 may translate along thetranslational axis 46 within the chamber 94 of the primary actuator 80,in the direction of the stop surface 44, causing the third pin 110 totranslate within the slot 100 of the primary actuator 80 and within theslot 43 of the cover 34. Translation of the secondary actuator 82 withinthe chamber 94 may further compress the biasing member 84 between thesecondary actuator 82 and the cover 34, thus increasing the potentialenergy of the biasing member 84. As illustrated in FIG. 2E, as thesecondary actuator 82 translates within the chamber 94 of the primaryactuator 80, the first pin 90 may be suspended between the primary andsecondary ramps 130, 132.

With reference to FIGS. 2F and 2G, as the spindle 122 continues torotate, the third pin 110 may reach the distal end 144 of the secondaryramp (FIG. 2F) and disengage from the secondary ramp 132 (FIG. 2G). Inparticular, the third pin 110 may disengage from the distal end 144 ofthe secondary ramp 132. In this regard, the third pin 110 of thesecondary actuator 82 and the first pin 90 of the primary actuator 80may simultaneously disengage the primary and secondary ramps 130, 132.After the third pin 110 disengages the secondary ramp 132, the biasingmember 84 may apply a force F2 on the secondary actuator 82, urging thesecondary actuator 82 in the direction of the primary actuator 80. Inparticular, the force F2 may cause the secondary actuator 82 totranslate within the chamber 94 of the primary actuator 80 away from thestop surface 44. It will be appreciated that the force F2 is greaterthan the force F1 due to the potential energy stored within the biasingmember 84, as previously described. As the secondary actuator 82translates along the translational axis 46, the third pin 110 maytranslate within the gap 146 until the secondary actuator 82 engages theprimary actuator 80.

When the secondary actuator 82 engages the primary actuator 80, thekinetic energy generated by the force F2, which is greater than theforce F1, is transmitted to the primary actuator 80. In this regard, thesecondary actuator 82 may impact the primary actuator 80 to deliver animpulse momentum transfer from the secondary actuator 82 to the primaryactuator 80. Accordingly, the second pin 92 of the primary actuator 80may engage the lower surface 74 of the control feature 70 and produce asecond torque impulse T2, greater than the first torque impulse T1,about the rotational axis 40 of the door subassembly 24. The secondtorque T2 may be greater than the previously-described torque producedby the force(s) (e.g., friction, ice, mud, etc.) preventing the doorsubassembly 24 from rotating into the open position. Accordingly, in thethird mode of operation, the second torque T2 may cause the doorsubassembly 24 to rotate about the rotational axis 40, as previouslydescribed, into the open position (FIG. 2B). If the second torque T2does not cause the door subassembly 24 to rotate about the rotationalaxis 40 during the third mode of operation, the sensor assembly 20 mayrepeat the third mode of operation one or more times. In this regard,the sensor assembly 20 may repeat the third mode of operation apredetermined number of times and/or repeat the third mode of operationuntil the door subassembly rotates about the rotational axis 40 into theopen position. When the door subassembly 24 reaches the open position,the first limit switch 170 may be switched to the “OFF” position, aspreviously described, thereby deactivating the driver 124 and causingthe spindle 122 to cease rotating.

The configuration of the sensor assembly 20, including the generation ofthe forces F1 and F2 and the torque impulses T1 and T2, may allow forthe use of a driver 124 that produces less torque about the rotationalaxis of the driveshaft 158 than might otherwise be used and/or requiredin order to move the door subassembly 24 from the closed position to theopen position. The use of a driver 124 that produces less torque aboutthe rotational axis of the driveshaft 158 can, in turn, reduce orprevent the need for sensors and other devices that might otherwise beused to measure the torque and/or force produced by the door subassembly24 upon moving from the open position to the closed position.Accordingly, the configuration of the sensor assembly 20 can result in aless complex (e.g., fewer components, smaller components, smallerpackaging footprint, etc.) and less expensive sensor assembly than mightotherwise be used and/or required.

With reference to FIGS. 5A-5C, another sensor assembly 20 a is shown.The structure and function of the sensor assembly 20 a may besubstantially similar to that of the sensor assembly 20, apart from anyexceptions described below and/or shown in the figures. Accordingly, thestructure and/or function of similar features will not be describedagain in detail. In addition, like reference numerals are usedhereinafter and in the drawings to identify like features, while likereference numerals containing letter extensions (i.e., “a”) are used toidentify those features that have been modified.

The sensor assembly 20 a may include a housing subassembly 22 a, a doorsubassembly 24 a, an actuator subassembly 26 a, and a driver subassembly28 a. As illustrated in FIG. 6, the housing subassembly 22 a may includea base 32 a and a cover 34 a. The door subassembly 24 a may be mountedto the base 32 a for rotation about a first axis of rotation 40 a, suchthat the door subassembly 24 a may be received within the aperture 36 ofthe base 32 a in a closed position (FIG. 5A) and an open position (FIG.5B).

The cover 34 a may include a chamber 42 a having a slot 43 a and a stopsurface 44 a. The chamber 42 a may define a generally prismaticconstruct (e.g., a circular cylinder, a rectangular cuboid, or otherpolygonal prism) having a first translational axis 46 a extendingthrough the stop surface 44 a. As illustrated in FIG. 5A, the firsttranslational axis 46 a may extend in a direction substantially parallel(e.g., +/− 5 degrees) to the first axis of rotation 40 a. As will beexplained in more detail below, in the assembled configuration, thechamber 42 a may receive the actuator subassembly 24 a for translationalong the first translational axis 46 a.

As illustrated in at least FIG. 6, the door subassembly 24 a may includea door 50 a, the sensing device 52, the axle 54, and the biasing member56. The door 50 a may include the baseplate 58, a first support arm 60a, and a second support arm 62 a. The first and second support arms 60a, 62 a may extend from the upper surface 64 of the baseplate 58. Thesecond support arm 62 a may include a control feature 70 a

The control feature 70 a may include a ramp surface 72 a. The rampsurface 72 a may include an arcuate shape and/or construction extendingfrom the second support arm 62 a. In some configurations the rampsurface 72 a may include a proximal portion 71 a and a distal portion 73a. The proximal portion 71 a may include a concave constructionextending away from the second support arm 62 a, and the distal portion73 a may include a convex construction extending away from the proximalportion 71 a. In this regard, the proximal and distal portions 71 a, 73a may define a spline curve extending from the second support arm 62 a.Accordingly, a distance between a proximal end 76 a of the controlfeature 70 a and the second support arm 62 a may be less than a distancefrom a distal end 78 a of the control feature 70 a and the secondsupport arm 62 a. As will be explained in more detail below, the controlfeature 70 a can control the movement of the door 50 a relative to thehousing subassembly 22 a.

As illustrated in FIGS. 5A and 6, the actuator subassembly 26 a mayinclude a primary actuator 80 a, the secondary actuator 82, and thebiasing member 84. The primary actuator 80 a may include a block 88 a, afirst pin 90 a, and a second pin 92 a. The block 88 a may include agenerally hollow construct defining an inner chamber 94 a. In someconfigurations, the block 88 a may include a generally circularcylinder. It will be appreciated, however, that the block 88 a mayinclude other cross-sectional shapes and configurations, such as anellipse, a square, or other polygonal shape, within the scope of thepresent disclosure. The block 88 a may include a proximal end 96 a, adistal end 98 a opposite the proximal end 96 a, and a slot 100 a. Theslot 100 a may extend through the block 88 a and into the chamber 94 afrom the distal end 98 a toward the proximal end 96 a. The proximal end96 a of the block 88 a may include a stop surface 101 a generally facingthe distal end 98 a of the block 88 a.

The first pin 90 a may extend from a first lateral side 102 a of theblock 88 a, and the second pin 92 a may extend from the proximal end 96a of the block 88 a. In this regard, the first pin 90 a may extend in afirst direction and the second pin 92 a may extend in a second directionthat is transverse to the first direction. In some configurations, thefirst direction may be substantially perpendicular to the seconddirection such that the first pin 90 a is substantially perpendicular tothe second pin 92 a.

In the assembled configuration, the slot 100 a may extend in a directionsubstantially parallel to the first translational axis 46 a. In thisregard, the primary actuator 80 a may be disposed within the chamber 42a of the cover 34 a such that the distal end 98 a faces the stop surface44 a of the cover 34 a, and such that the chamber 42 a is incommunication with the inner chamber 94 a of the block 88 a. Inparticular, the primary actuator 80 a may be translatably disposedwithin the chamber 42 a such that the block 88 a can translate in adirection substantially parallel to the first translational axis 46 aand to the slot 100 a. In the assembled configuration, the first pin 90a may extend through the slot 43 a of the cover 34 a, and the second pin92 a may engage the control feature 70 a (e.g., the ramp surface 72 a)of the door 50 a.

As illustrated in FIGS. 5A and 6, the driver subassembly 28 a mayinclude a spindle 122 a, a first drive mechanism 123, and the driver124. The spindle 122 a may include a proximal end 126 a, a distal end128 a, a primary ramp 130 a, a secondary ramp 132 a, and a second drivemechanism 134 a. The second drive mechanism 134 a may include a gearwheel 150 a. In some configurations, the gear wheel 150 a may bedisposed proximate to the distal end 128 a of the spindle 122 a. Thegear wheel 150 a may include a series of gear teeth 152 a. Rotation ofthe gear wheel 150 a may cause the spindle 122 a to rotate about asecond axis of rotation 136 a that extends in a direction substantiallyparallel (e.g., +/− 5 degrees) to the first axis of rotation 40 a.

The first drive mechanism 123 may include a gear wheel 153 configured torotate about a third axis of rotation 155. The third axis of rotation155 may extend in a direction transverse to the second axis of rotation136 a. For example, in some configurations the third axis of rotation155 may extend in a direction generally perpendicular to the second axisof rotation 136 a. In some configurations, the gear wheel 153 may bedisposed proximate to the distal end 128 a of the spindle 122 a. Thegear wheel 153 may include a first series of gear teeth 157 configuredto engage the gear teeth 152 a of the gear wheel 150 a and a secondseries of gear teeth 159 configured to engage the worm gear 160 of thedriver 124. Accordingly, rotation of the worm gear 160 may rotate thegear wheel 153, which causes the gear wheel 150 a and the spindle 122 ato rotate about the second axis of rotation 136 a.

A method of operating the sensor assembly 20 a will now be describedwith reference to FIGS. 5A-5C. As previously discussed, the method ofoperating the sensor assembly 20 a may be substantially similar to themethod of operating the sensor assembly 20, except as otherwise providedherein. Accordingly, only the differences between the method ofoperating the sensor assembly 20 a and the method of operating thesensor assembly 20 will be described in detail herein.

As illustrated in FIG. 5A, a first mode of operation may begin with thedoor subassembly 24 a in a closed position. As the worm gear 160 rotatesin the first direction, the worm gear 160 engages the gear teeth 159 ofthe gear wheel 153, causing the spindle 122 a to rotate in a seconddirection about the second axis of rotation 136 a. As the spindle 122 arotates in the second direction, the first pin 90 a may disengage theprimary ramp 130 a. In particular, the first pin 90 a may translate in afirst direction, substantially parallel to the translational axis 146 a,from the distal end 140 a of the primary ramp 130 a to the proximal end138 a of the primary ramp 130 a. In this regard, the biasing member 84may apply the force F1 on the secondary actuator 82, urging thesecondary actuator 82 in the direction of the primary actuator 80 a,and, in turn, urging the primary actuator 80 a in the first direction.As the first pin 90 a translates in the first direction, the first pin90 a of the primary actuator 80 a and the third pin 110 of the secondaryactuator 82 may translate within the slot 43 a of the cover 34 a, andthe second pin 92 a of the primary actuator 80 a may engage the controlfeature 70 a of the door subassembly 24 a. In this regard, the secondpin 92 a may move along (e.g., slide) the ramp surface 72 a of thecontrol feature 70 a. In particular, the second pin 92 a may slide fromthe proximal portion 71 a of the ramp surface 72 a to the distal portion73 a of the ramp surface 72 a. For example, the second pin 92 a mayslide along the concave portion of the proximal portion 71 a to theconvex portion of the distal portion 73 a. In this regard, the secondpin 92 a may apply a force on the ramp surface 72 a, creating the firsttorque T1 about the rotational axis 40 a of the door subassembly 24 a,and causing the door subassembly 24 a to rotate about the rotationalaxis 40 a. As the door subassembly 24 a rotates about the rotationalaxis 40 a into the open position (FIG. 5B), the second pin 92 a mayslide across the control feature 70 a from the end 76 a to the end 78 auntil the door subassembly 24 a reaches the open position. When the doorsubassembly 24 a rotates from the closed position (FIG. 5A) to the openposition (FIG. 5B), the first limit switch 170 may be switched to an“OFF” position, thereby deactivating the driver 124.

During a second mode of operation, as the spindle 122 a rotates in thesecond direction, the first pin 90 a may move along the primary ramp 130a from the proximal end 138 a to the distal end 140 a. As the first pin90 a moves along the primary ramp 130 a, the second pin 92 a of theprimary actuator 80 a may move along (e.g., slide) the ramp surface 72 aof the control feature 70 a as the primary and secondary actuators 80 a,82 translate along the translational axis 46 a within the chamber 42 aof the cover 34 a. In particular, the second pin 92 a may slide from thedistal portion 73 a of the ramp surface 72 a to the proximal portion 71a of the ramp surface 72 a. For example, the second pin 92 a may slidealong the convex portion of the distal portion 73 a to the concaveportion of the proximal portion 71 a. As the second pin 92 a slidesalong the ramp surface 72 a, the biasing member 56 may apply a torqueabout the rotational axis 40 that is opposite the first torque T1produced by the second pin 92 a. Accordingly, the biasing member 56 maycause the door subassembly 24 a to rotate about the rotational axis 40 afrom the open position (FIG. 5B) to the closed position (FIG. 5A).Accordingly, as the primary and secondary actuators 80 a, 82 translatewithin the chamber 42 a towards the stop surface 44 a, the secondaryactuator 82 may compress the biasing member 84 as the biasing member 56moves the door subassembly 24 a into the closed position.

During a third mode of operation, the driveshaft 158 and the worm gear160 may rotate in the first direction, causing the spindle 122 a torotate in the second direction about the second axis of rotation 136 a.As the spindle 122 a rotates in the second direction, the first pin 90 amay disengage the primary ramp 130 a, and the second pin 92 a may engagethe ramp surface 72 a of the control feature 70 a. As previouslydescribed, however, during the third mode of operation, the doorsubassembly 24 a may be prevented from rotating about the rotationalaxis 40 a. For example, friction between various moving components inthe sensor assembly 20 a, or an obstruction, such as ice or mud, mayprevent the door subassembly 24 a from rotating into the open position(FIG. 5B). In particular, the torque generated by the force(s)preventing the door subassembly 24 a from rotating into the openposition may be greater than the first torque T1 generated by the forceF1 of the biasing member 84. Accordingly, when the first pin 90 adisengages the primary ramp 130 a, as previously described, the doorsubassembly 24 a may not trigger the first limit switch 170. If thefirst limit switch 170 is not triggered because, for example, the doorsubassembly 24 a does not rotate into the open position when the firstpin 90 a disengages the primary ramp 130 a, the driver 124 may remainactivated such that the driveshaft 158 continues to rotate the spindle122 a in the second direction about the second axis of rotation 136 a.

As the spindle 122 a continues rotating in the second direction, thethird pin 110 may engage the proximal end 142 a of the secondary ramp132 a and continue moving along the secondary ramp 132 a from theproximal end 142 a to the distal end 144 a. As the third pin 110 movesalong the secondary ramp 132 a, the secondary actuator 82 a maytranslate along the translational axis 46 a within the chamber 94 a ofthe primary actuator 80 a, in the direction of the stop surface 44 a,causing the third pin 110 to translate within the slot 100 a of theprimary actuator 80 a and within the slot 43 a of the cover 34 a.Translation of the secondary actuator 82 within the chamber 94 a mayfurther compress the biasing member 84 between the secondary actuator 82and the cover 34 a, thus increasing the potential energy of the biasingmember 84.

With reference to FIG. 5C, as the spindle 122 a continues to rotate, thethird pin 110 may disengage the secondary ramp 132 a. In particular, thethird pin 110 may disengage from the distal end 144 a of the secondaryramp 132 a. In this regard, the third pin 110 of the secondary actuator82 and the first pin 90 a of the primary actuator 80 a maysimultaneously disengage the primary and secondary ramps 130 a, 132 a.After the third pin 110 disengages the secondary ramp 132 a, the biasingmember 84 may apply the force F2 on the secondary actuator 82, urgingthe secondary actuator 82 in the direction of the primary actuator 80 a.In particular, the force F2 may cause the secondary actuator 82 totranslate within the chamber 94 a of the primary actuator 80 a, awayfrom the stop surface 44 a, until the secondary actuator 82 engages theprimary actuator 80 a. It will be appreciated that the force F2 isgreater than the force F1 due to the potential energy stored within thebiasing member 84, as previously described. Accordingly, when thesecondary actuator 82 engages the primary actuator 80 a, the kineticenergy generated by the force F2 is transmitted to the primary actuator80 a. Accordingly, the second pin 92 a of the primary actuator 80 a mayengage the ramp surface 72 a of the control feature 70 a and produce thesecond torque T2, greater than the first torque T1, about the rotationalaxis 40 a of the door subassembly 24 a. The second torque T2 may begreater than the previously-described torque produced by the force(s)(e.g., friction, ice, mud, etc.) preventing the door subassembly 24 afrom rotating into the open position. Accordingly, in the third mode ofoperation, the second torque T2 may cause the door subassembly 24 a torotate about the rotational axis 40 a, as previously described, into theopen position (FIG. 5B). When the door subassembly 24 a reaches the openposition, the first limit switch 170 may be switched to the “OFF”position, as previously described, thereby deactivating the driver 124and causing the spindle 122 a to cease rotating.

With reference to FIGS. 7-9, another sensor assembly 20 b is shown. Thestructure and function of the sensor assembly 20 b may be substantiallysimilar to that of the sensor assembly 20, apart from any exceptionsdescribed below and/or shown in the figures. Accordingly, the structureand/or function of similar features will not be described again indetail. In addition, like reference numerals are used hereinafter and inthe drawings to identify like features, while like reference numeralscontaining letter extensions (i.e., “b”) are used to identify thosefeatures that have been modified.

As illustrated in FIG. 9, the sensor assembly 20 b may include a housingsubassembly 22 b, the door subassembly 24, an actuator subassembly 26 b,and a driver subassembly 28 b. The housing subassembly 22 b may includea base 32 b and a cover 34 b. With reference to FIG. 7, the base 32 bmay include a lower surface 35 b, an aperture 36 b, a rotation feature38 b (e.g., a hub and/or an axle), and a support 39. The aperture 36 bmay extend through the base 32 b such that the lower surface 35 bgenerally surrounds the aperture 36 b. The rotation feature 38 b maydefine a first axis of rotation 40 b. As will be explained in moredetail below, in an assembled configuration, the aperture 36 b androtation feature 38 b may receive the door subassembly 24. Inparticular, the door subassembly 24 may be mounted to the rotationfeature 38 b for rotation about the first axis of rotation 40 b suchthat the door subassembly 24 is receivable within the aperture 36 b in astowed or closed position (FIG. 8A) and a deployed or open position(FIG. 8B).

The support 39 may include a rotation feature 41 (e.g., a hub and/or anaxle), an annular rib 45, and a recess 47. The rotation feature 41 maydefine a second axis of rotation 136 b. As illustrated in FIG. 8A, thesecond axis of rotation 136 b may extend in a direction substantiallyparallel (e.g., +/− 5 degrees) to the first axis of rotation 40 b. Aswill be explained in more detail below, the actuator subassembly 26 bmay be mounted to the rotation feature 41 for rotation about the secondaxis of rotation 136 b. The annular rib 45 may surround the second axisof rotation 136 b. In this regard, the annular rib 45 may extend fromthe support 39 in an axial direction relative to the second axis ofrotation 136 b. As will be explained in more detail below, in anassembled configuration, the annular rib 45 may guide the rotation ofthe actuator subassembly 26 b relative to the housing subassembly 22 b.

The recess 47 may be formed in the support 39. In particular, the recess47 may extend into the support 39 in an axial direction relative to thesecond axis of rotation 136 b. The recess 47 may include a ramp surface48. As will be explained in more detail below, in the assembledconfiguration, the recess 47 may receive a pin 90 b of the actuatorsubassembly 26 and thus allow the pin 90 b to move in a first axialdirection relative to the second axis of rotation 136 b. The rampsurface 48 may engage the pin 90 b of the actuator subassembly 26 andthus allow the pin 90 b to move in a second axial direction (oppositethe first axial direction) relative to the second axis of rotation 136b.

As illustrated in FIGS. 8A and 9, the actuator subassembly 26 b mayinclude an actuator 80 b, a first biasing member 85, and a secondbiasing member 84 b. As illustrated in FIG. 9, the actuator 80 b mayinclude a block 88 b, the first pin 90 b, and a second pin 92 b. Theblock 88 b may include a proximal end 96 b and a distal end 98 bopposite the proximal end 96 b. An annular flange 99 may extend from thedistal end 98 b of the block 88 b, such that the annular flange 99 andthe distal end 98 b of the block 88 b define a chamber 94 b A catch 101may extend radially (relative to the second axis of rotation 136 b) fromthe annular flange 99 and/or axially (relative to the second axis ofrotation 136 b) from the distal end 98 b. In this regard, the catch 101may be disposed within the chamber 94 b.

The first pin 90 b may include a stem portion 103 and a head portion 106supported by the stem portion 103. As will be explained in more detailbelow, in the assembled configuration, the first pin 90 b may betranslatably disposed within the actuator subassembly 26 b and/or thedriver subassembly 28 b. In this regard, the first pin 90 b may besupported by the driver subassembly 28 b for translation in a directiongenerally parallel (+/− 5 degrees) to the second axis of rotation 136 bor for orbital movement about the second axis of rotation 136 b. Thesecond pin 92 b may extend from the proximal end 96 b of the block 88 bin a direction substantially parallel (+/− 5 degrees) to the first pin90 b, such that, in the assembled configuration, the second pin 92 b isreceived within the control feature 70 of the door subassembly 24.

The first biasing member 85 may include a proximal end 115 and a distalend 117. In some configurations, the first biasing member 85 may be acompression coil spring extending from the proximal end 115 to thedistal end 117. In the assembled configuration, the first biasing member85 may be disposed about the stem portion 103 of the first pin 90 b. Forexample, the first biasing member 85 may be disposed about the stemportion 103 such that the proximal end 115 engages the driversubassembly 28 b and the distal end 117 engages the head portion 106 ofthe first pin 90 b. Accordingly, as will be explained in more detailbelow, upon translation of the first pin 90 b in the direction of thedoor subassembly 24 b, the first pin 90 b may compress the first biasingmember 85.

As illustrated in FIG. 9, the second biasing member 84 b may include aproximal end 126 b and a distal end 128 b. The second biasing member 84b may be disposed about the second axis of rotation 136 b such that theproximal end 126 b engages the housing subassembly 22 b and the distalend 128 b is configured to selectively engage the actuator subassembly26 b. In particular, the second biasing member 84 b may be disposedwithin the chamber 94 b of the block 88 b, such that the proximal end126 b engages the rotation feature 41 of the base 32 b, and the distalend 128 b engages the catch 101 of the actuator subassembly 22 b. Inthis regard, the second biasing member 84 b may include a clock spring.Accordingly, as will be explained in more detail below, winding thesecond biasing member 84 b may increase the elastic potential energystored within the second biasing member 84 b.

As illustrated in FIGS. 7 and 9, the driver subassembly 28 b may includethe driver 124, a drive mechanism 134 b, and one or more gears 135. Thedrive mechanism 134 b may include a proximal end 127, a distal end 129,an aperture 130 b, and a gear wheel 150 b. In the assembledconfiguration, the drive mechanism 134 b may be supported by the housingsubassembly 22 b for rotation about the second axis of rotation 136 b.In this regard, the proximal and distal ends 127, 129 may definegenerally radially extending surfaces relative to the second axis ofrotation 136 b.

The aperture 130 b may extend through the proximal and distal ends 127,129 of the drive mechanism 134 b. In particular, the aperture 130 b mayextend in an axial direction relative to the second axis of rotation 136b. As illustrated in FIG. 8A, the aperture 130 b may include acounterbore portion 138 b formed in the distal end 129 of the drivemechanism 134 b. As will be explained in more detail below, in theassembled configuration, the aperture 130 b may receive the first pin 90b for translation therein. In this regard, the counterbore portion 138 bmay be configured to intermittently receive the head portion 106 of thefirst pin 90 b as the first pin 90 b translates within the aperture 130b.

The gear wheel 150 b may include a series of gear teeth 152 b extendingradially outward relative to the second axis of rotation 136 b.Accordingly, rotation of the gear wheel 150 b may cause the drivemechanism 134 b to rotate about the second axis of rotation 136 b.

The driver 124 may be configured to rotate the drive mechanism 134 babout the second axis of rotation 136 b. For example, in the assembledconfiguration, the worm gear 160 may be engaged with the gears 135, suchthat rotation of the worm gear 160 causes the drive mechanism 134 b torotate about the second axis of rotation 136 b.

A method of operating the sensor assembly 20 b will now be describedwith reference to FIGS. 8A and 8B. As previously discussed, the methodof operating the sensor assembly 20 b may be substantially similar tothe method of operating the sensor assembly 20, except as otherwiseprovided herein. Accordingly, only the differences between the method ofoperating the sensor assembly 20 b and the method of operating thesensor assembly 20 will be described in detail herein.

As illustrated in FIG. 8A, a first mode of operation may begin with thedoor subassembly 24 in a closed position. As the worm gear 160 rotatesin the first direction, the worm gear 160 engages one of the gears 135,causing the drive mechanism 134 b to rotate in a second direction aboutthe second axis of rotation 136 b. As the drive mechanism 134 b rotatesin the second direction, the head portion 106 of the first pin 90 a maymove along the annular rib 45 and the stem portion 103 of the first pin90 a may engage the catch 101 of the actuator 80 b. In this regard, thefirst pin 90 a may orbit about second axis of rotation 136 b, causingthe actuator 80 b to rotate about the second axis of rotation 136 b. Asthe actuator 80 b rotates about the second axis of rotation 136 b, thecatch 101 engages the distal end 128 b of the second biasing member 84 bin order to wind, and increase the potential energy of, the secondbiasing member 84 b.

The first pin 90 a may slide along the annular rib 45 of the support 39until the first pin 90 b is aligned with the recess 47. In this regard,once the first pin 90 b is aligned with the recess 47, the first biasingmember 85 may apply a force on the head portion 106 of the first pin 90b, causing the first pin 90 b to translate within the aperture 130 buntil the head portion 106 is disposed within the recess 47 of thesupport 39. Once the head portion 106 is disposed within the recess 47,the distal end 128 b of the second biasing member 84 b may engage thecatch 101 such that the force of the second biasing member 84 b urgesthe actuator 80 a to rotate in the first direction about the second axisof rotation 136 b.

As the actuator 80 b rotates in the first direction about the secondaxis of rotation 136 b, the second pin 92 b may translate within thecontrol feature 70 of the door subassembly 24. For example, the secondpin 92 b may engage the lower surface 74 of the control feature 70. Inthis regard, the second pin 92 b may apply a force on the lower surface74, creating the first torque T1 about the rotational axis 40 b of thedoor subassembly 24, and causing the door subassembly 24 to rotate aboutthe rotational axis 40 b. In some configurations, the biasing member 56may cause the door subassembly 24 to rotate about the rotational axis 40b in lieu of, or in addition to, the first torque T1 created by thesecond pin 92 b. As the door subassembly 24 rotates about the rotationalaxis 40 b into the open position (FIG. 8B), the second pin 92 b maytranslate within the control feature 70 to the end 78 until the doorsubassembly 24 reaches the open position.

During a second mode of operation, as the drive mechanism 134 b rotatesin the second direction, the first pin 90 a may exit the recess 47. Inparticular, the first pin 90 a may slide along the ramp surface 48 ofthe support 39 until the head portion 106 has exited the recess 47. Inthis regard, as the first pin 90 a exits the recess 47, the head portion106 and the support 39 may compress the first biasing member 85. Oncethe first pin 90 a has exited the recess 47, the head portion 106 mayslide along the annular rib 45 of the support 39 while the stem portion103 engages the catch 101, thus causing the actuator 80 b to rotate inthe second direction about the second axis of rotation 136 b. As theactuator 80 b rotates about the second axis of rotation 136 b, the catch101 engages the distal end 128 b of the second biasing member 84 b inorder to wind, and increase the potential energy of, the second biasingmember 84 b, as previously described.

As the actuator 80 b rotates about the second axis of rotation 136 b,the second pin 92 b of the actuator 80 b may translate within thecontrol feature 70 of the door subassembly 24. In this regard, thesecond pin 92 b may disengage the end 78 of the control feature 70 andengage the upper surface 72 of the control feature 70. The second pin 92b may apply a force on the upper surface 72, creating a torque about therotational axis 40 b of the door subassembly 24, and causing the doorsubassembly 24 to rotate about the rotational axis 40 b. The torquecreated by the second pin 92 b may be greater than an opposing torquegenerated by the biasing member 56 and/or the second biasing member 84b. Accordingly, as the actuator 80 rotates in the second direction, theactuator 80 b may compress the second biasing member 84 b as the secondpin 92 b moves the door subassembly 24 into the closed position (FIG.8A).

During a third mode of operation, the drive mechanism 134 b may rotatein the second direction until the first pin 90 b is aligned with therecess 47 of the support 39. As previously described, however, duringthe third mode of operation, the door subassembly 24 may be preventedfrom rotating about the rotational axis 40 b. For example, frictionbetween various moving components in the sensor assembly 20 b, or anobstruction, such as ice or mud, may prevent the door subassembly 24from rotating into the open position (FIG. 8B). In particular, thetorque generated by the force(s) preventing the door subassembly 24 fromrotating into the open position may be greater than the first torque T1generated by the force of the second biasing member 84 b. Accordingly,when the first pin 90 b is aligned with the recess 47, as previouslydescribed, the door subassembly 24 may not trigger the first limitswitch 170. If the first limit switch 170 is not triggered because, forexample, the door subassembly 24 does not rotate into the open positionwhen the first pin 90 b is aligned with the recess 47, the driver 124may remain activated such that the driveshaft 158 continues to rotatethe drive mechanism 134 b in the second direction about the second axisof rotation 136 b.

As the drive mechanism 134 b continues rotating in the second direction,the second pin 92 b may remain engaged with the catch 101 in order torotate the actuator 80 b about the second axis of rotation 136 b. As theactuator 80 b rotates about the second axis of rotation 136 b, the catch101 engages the distal end 128 b of the second biasing member 84 b inorder to wind, and increase the potential energy of, the second biasingmember 84 b, as previously described.

With reference to FIGS. 8A and 8B, the drive mechanism 134 b maycontinue rotating in the second direction until the first pin 90 b isaligned with the recess 47 of the support 39. In this regard, the drivemechanism 134 b may rotate at least 360 degrees. Once the first pin 90 bis aligned with the recess 47, such that the head portion 106 isreceived within the recess 47, the second biasing member 84 b may applythe force F2 on the catch 101, urging the actuator 80 b to rotate in thefirst direction. In particular, the force F2 may cause the actuator 80 bto rotate with the kinetic energy generated by the force F2, which isgreater than the force F1. Accordingly, the second pin 92 b may engagethe lower surface 74 of the control feature 70 and produce the secondtorque T2, greater than the first torque T1, about the rotational axis40 b of the door subassembly 24. The second torque T2 may be greaterthan the previously-described torque produced by the force(s) (e.g.,friction, ice, mud, etc.) preventing the door subassembly 24 fromrotating into the open position. Accordingly, in the third mode ofoperation, the second torque T2 may cause the door subassembly 24 torotate about the rotational axis 40 b, as previously described, into theopen position (FIG. 8B). When the door subassembly 24 reaches the openposition, the first limit switch 170 may be switched to the “OFF”position, as previously described, thereby deactivating the driver 124and causing the drive mechanism 134 b to cease rotating.

The foregoing description has been provided for purposes of illustrationand description. It is not intended to be exhaustive or to limit thedisclosure. Individual elements or features of a particularconfiguration are generally not limited to that particularconfiguration, but, where applicable, are interchangeable and can beused in a selected configuration, even if not specifically shown ordescribed. The same may also be varied in many ways. Such variations arenot to be regarded as a departure from the disclosure, and all suchmodifications are intended to be included within the scope of thedisclosure.

What is claimed is: 1-15. (canceled)
 16. A method of operating a closureassembly comprising a housing, a door movably coupled to the housing,and an actuator, the method comprising: storing a first amount of energyin an energy storage device; releasing the first amount of energy tomove the door from a closed state to an open state; storing a secondamount of energy in the energy storage device if the door remains in theclosed state following release of the first amount of energy, the secondamount of energy being greater than the first amount of energy; andreleasing the second amount of energy to move the door from the closedstate to the open state.
 17. The method of claim 16, further comprisingexposing a sensor when the door is in the open state and hiding thesensor when the door is in the closed state.
 18. The method of claim 16,wherein releasing the first amount of energy includes producing a firstmomentum impulse with the first amount of energy to move the door fromthe closed state to the open state.
 19. The method of claim 18, whereinreleasing the second amount of energy includes producing a secondmomentum impulse to move the door from the closed state to the openstate, the second momentum impulse being greater than the first momentumimpulse.
 20. A method of operating a closure assembly comprising ahousing, a door movably coupled to the housing, and an actuator, themethod comprising: engaging the door with the actuator to apply a firstforce to move the door from a closed state to an open state to expose asensor; and engaging the door with the actuator to apply a second forcegreater than the first force to move the door from the closed state tothe open state to expose the sensor when the first force fails to movethe door from the closed state to the open state.
 21. The method ofclaim 20, wherein the door is supported by the housing for rotationabout a first axis, the first force producing a first torque about thefirst axis and the second force producing a second torque about thefirst axis.
 22. The method of claim 20, wherein engaging the door withthe actuator to produce the second force includes producing a firstoccurrence of the second force and a second occurrence of the secondforce.
 23. The method of claim 20, wherein the door includes a controlfeature and the actuator includes a pin, and wherein engaging the doorwith the actuator includes moving the pin along a surface of controlfeature.
 24. The method of claim 20, wherein the closure assemblyfurther comprises a spindle having a ramp surface, the method furthercomprising rotating the spindle about an axis of rotation in a firstdirection such that the actuator engages the ramp surface to produce thefirst force.
 25. The method of claim 24, further comprising: rotatingthe spindle in the first direction about the axis of rotation to producethe first force and the second force; and rotating the spindle in thefirst direction about the axis of rotation to produce a third force, thethird force being opposite the first force and the second force to movethe door from the open state to the closed state.
 26. A method ofoperating a closure assembly comprising a housing, a door movablycoupled to the housing, and an actuator, the method comprising: engagingthe door with the actuator to apply a first force to move the door froma closed state to an open state; and engaging the door with the actuatorto apply an impact force to move the door from the closed state to theopen state when the first force fails to move the door from the closedstate to the open state.
 27. The method of claim 26, wherein the door issupported by the housing for rotation about a first axis, the firstforce producing a first torque about the first axis and the impact forceproducing a second torque about the first axis.
 28. The method of claim26, further comprising exposing a sensor when the door is in the openstate.